W-patterned tools for transporting/handling pairs of disks

ABSTRACT

Various apparatus and methods are provided for handling and transporting pairs of disks. A transfer tool engages a pair of disks in gap merge orientation along the outer perimeter edge of the disks and maintains the orientation while transferring the pair of disks to a second location where the disks are transferred to other equipment or subjected to processing. Various disks carriers are also provided for handling and transporting multiple pairs of disks in gap merge orientation.

CROSS REFERENCE TO RELATED APPLICATION

[0001] Priority is claimed from U.S. Provisional Patent ApplicationSerial No. 60/379,008 filed May 9, 2002, which is incorporated byreference herein in its entirety.

[0002] The subject matter of the present application is related to thefollowing applications, each of which has a filing date of May 9, 2003:Attorney Docket No. 3123-479 entitled Single-Sided Sputtered MagneticRecording Disks to Clasara et al.; Attorney Docket No. 3123-480 entitledDual Disk Transport Mechanism Processing Two Disks Tilted Toward EachOther to Grow et al.; Attorney Docket No. 3123-481 entitledInformation-Storage Media With Dissimilar Outer Diameter and/or InnerDiameter Chamfer Designs On Two Sides to Clasara et al.; Attorney DocketNo. 3123-483 entitled Method of Merging Two Disks Concentrically WithoutGap Between Disks to Buitron; Attorney Docket No.3123-484 entitledApparatus for Combining or Separating Disk Pairs Simultaneously toBuitron et al.; Attorney Docket No. 3123-485 entitled Method ofSimultaneous Two-Disk Processing of Single-Sided Magnetic RecordingDisks to Buitron et al.; Attorney Docket No. 3123-491 entitled Methodfor Servo Pattern Application on Single-Side Processed Disks in a MergedState to Valeri; Attorney Docket No.3123-518 entitled Method forSimultaneous Two-Disk Texturing to Buitron et al.; Attorney Docket No.3123-519 entitled Cassette for Holding Disks of Multiple Form Factors toBuitron et al.; Attorney Docket No. 3123-521 entitled Automated MergeNest for Pairs of Magnetic Storage Disks to Crofton et al.; AttorneyDocket No. 3123-522 entitled Apparatus for Simultaneous Two-DiskScrubbing and Washing to Crofton et al.; Attorney Docket No. 3123-523entitled Cassette Apparatus for Holding 25 Pairs of Disks forManufacturing Process to Buitron et al.; and Attorney Docket No.3123-524 entitled Method of Lubricating Multiple Magnetic Storage Disksin Close Proximity to Buitron et al. Each of these applications isincorporated by reference in its entirety as if stated herein.

FIELD OF THE INVENTION

[0003] The present invention is directed to various apparatus andmethods for handling pairs of hard memory disks. More specifically, theapparatus and methods apply to handling a single pair of disks or aplurality of pairs of disks in various applications including themanufacture of single-sided hard memory disks and post-manufactureprocesses.

BACKGROUND OF THE INVENTION

[0004] Hard disk drives are an efficient and cost effective solution fordata storage. Depending upon the requirements of the particularapplication, a disk drive may include anywhere from one to eight harddisks and data may be stored on one or both surfaces of each disk. Whilehard disk drives are traditionally thought of as a component of apersonal computer or as a network server, usage has expanded to includeother storage applications such as set top boxes for recording and timeshifting of television programs, personal digital assistants, cameras,music players and other consumer electronic devices, each havingdiffering information storage capacity requirements.

[0005] Typically, hard memory disks are produced with functionalmagnetic recording capabilities on both sides or surfaces of the disk.In conventional practice, these hard disks are produced by subjectingboth sides of a raw material substrate disk, such as glass, aluminum orsome other suitable material, to numerous manufacturing processes.Active materials are deposited on both sides of the substrate disk andboth sides of the disk are subject to full processing such that bothsides of the disk may be referred to as active or functional from amemory storage stand point. The end result is that both sides of thefinished disk have the necessary materials and characteristics requiredto effect magnetic recording and provide data storage. These aregenerally referred to as double-sided process disks. Assuming bothsurfaces pass certification testing and have no defects, both sides ofthe disk may be referred to as active or functional for memory storagepurposes. These disks are referred as double-sided test pass disks.Double-sided test pass disks may be used in a disk drive fordouble-sided recording.

[0006] Conventional double-sided processing of hard memory disksinvolves a number of discrete steps. Typically, twenty-five substratedisks are placed in a plastic cassette, axially aligned in a single row.Because the disk manufacturing processes are conducted at differentlocations using different equipment, the cassettes are moved from workstation to work station. For most processes, the substrate disks areindividually removed from the cassette by automated equipment, bothsides or surfaces of each disk are subjected to the particular process,and the processed disk is returned to the cassette. Once each disk hasbeen fully processed and returned to the cassette, the cassette istransferred to the next work station for further processing of thedisks.

[0007] More particularly, in a conventional double-sided diskmanufacturing process, the substrate disks are initially subjected todata zone texturing. Texturing prepares the surfaces of the substratedisks to receive layers of materials which will provide the active ormemory storage capabilities on each disk surface. Texturing maytypically be accomplished in two ways: fixed abrasive texturing or freeabrasive texturing. Fixed abrasive texturing is analogous to sanding, inwhich a fine grade sand paper or fabric is pressed against both sides ofa spinning substrate disk to roughen or texturize both surfaces. Freeabrasive texturing involves applying a rough woven fabric against thedisk surfaces in the presence of a slurry. The slurry typically containsdiamond particles, which perform the texturing, a coolant to reduce heatgenerated in the texturing process and deionized water as the basesolution. Texturing is typically followed by washing to removeparticulate generated during texturing. Washing is a multi-stage processand usually includes scrubbing of the disk surfaces. The texturedsubstrate disks are then subjected to a drying process. Drying isperformed on an entire cassette of disk drives at a time. Followingdrying, the textured substrate disks are subjected to laser zonetexturing. Laser zone texturing does not involve physically contactingand applying pressure against the substrate disk surfaces like data zonetexturing. Rather, a laser beam is focused on and interacts withdiscrete portions of the disk surface, primarily to create an array ofbumps for the head and slider assembly to land on and take off from.Laser zone texturing is performed one disk at a time. The disks are thenwashed again. Following a drying step, the disks are individuallysubjected to a process which adds layers of material to both surfacesfor purposes of creating data storage capabilities. This can beaccomplished by sputtering, deposition or by other techniques known topersons of skill in the art. Following the addition of layers ofmaterial to each surface, a lubricant layer typically is applied. Thelubrication process can be accomplished by subjecting an entire cassetteof disks to a liquid lubricant; it does not need to be done one disk ata time. Following lubrication, the disks are individually subjected tosurface burnishing to remove asperities, enhance bonding of thelubricant to the disk surface and otherwise provide a generally uniformfinish to the disk surface. Following burnishing, the disks aresubjected to various types of testing. Examples of testing include glidetesting to find and remove disks with asperities that could affectflying at the head/slider assembly and certification testing which iswriting to and reading from the disk surfaces. Certification testing isalso used to locate and remove disks with defects that make the surfaceunuseable for data storage. The finished disks can then be subjected toa servo-writing process and placed in disk drives, or placed in diskdrives then subjected to servo-writing. The data zone texturing, laserzone texturing, scrubbing, sputtering, burnishing and testing processesare done one disk at a time, with each surface of a single disk beingprocessed simultaneously.

[0008] Although the active materials and manufacturing processes, bytheir nature, are difficult and expensive to employ, over the years, thetechnology used to manufacture hard memory disks has rapidly progressed.As a result, the density of information that can be stored on a disksurface is remarkable. Indeed, double-sided test pass disks used inpersonal computers have much greater storage capacity than mostconsumers require during the useful life of the computer. Consumers thusare forced to pay substantial amounts for excess storage capacity andthe components to access the excess storage capacity. This has causedsome disk drive manufacturers, in some current applications, tomanufacture and sell disk drives which utilize only one side of adouble-sided test pass disk for storage purposes or which use the goodside of a double-sided process disk where one surface passedcertification testing and the second surface failed. In either case, thesecond surface, despite being fully processed, is unused. However, thedisk drive manufacturer reduces its cost by eliminating the mechanicaland electrical components needed to access the unused disk surface.These disk drives are referred to as single-side drives and aretypically used in low-end or economy disk drives to appeal to the lowcost end of the marketplace. Although this approach may reduce somecost, it does not reduce the wasted cost of manufacturing the unusedstorage surface of each disk. Thus, substantial savings can be achievedby not only manufacturing disks with a single active or functional side,but doing so in a cost-effective manner.

[0009] In contrast to a double-sided disk, a single-sided disk has onlyone functional memory surface with active recording materials. It is nota double-sided process disk where one side is not accessed or where oneside has failed testing. Rather, manufacturing processes are applied ina controlled manner only to one side of the disk using uniquesingle-sided processing techniques. In contrast to conventionaldouble-sided disks, active recording materials are only applied to, andfull processing is only conducted on, one side of the disk. Thus,substantial savings are achieved by eliminating processing the secondside of each disk.

[0010] Additionally, the present invention achieves advantages byutilizing conventional double-sided disk manufacturing equipment andprocesses, with limited modification. The present invention enablessimultaneous processing of two substrate disks through the sameequipment and processes used to manufacture double-sided disks.Simultaneously processing two substrate disks results in the productionof two single-sided disks in the same time and using essentially thesame equipment as currently is used in the production of onedouble-sided disk. However, each single-sided disk has only a singleactive or functional surface. For illustrative purposes FIG. 1 shows aside-by-side schematic representation of the processing of onedouble-sided disk D_(d), depicted on the left side of FIG. 1, versus thesimultaneous processing of two single-sided disks D_(s), depicted on theright side of FIG. 1. In each case, the double-sided disk or the twosingle-sided disks are subjected to the same process steps 1 through N,but the single-sided disk processing produces two disks in the same timethe double-sided disk processing produces one disk.

[0011] A benefit provided by simultaneous single-sided processing ofdisks is a substantial cost savings achieved by eliminating theapplication of materials to and processing of one side of each disk. Afurther, and potentially significant cost savings can be achieved byutilizing existing double-sided disk processing equipment, with limitedmodification, to process pairs of single-sided disks. A still furtherbenefit is a substantial increase in production (or reduction inprocessing time depending upon perspective). By utilizing existingdouble-sided disk processing equipment, approximately twice theproductivity of a conventional double-sided production process isachieved (on the basis of numbers of disks produced) in the productionof single-sided disks. Moreover, these increased productivity levels areachieved at approximately the same material cost, excepting thesubstrate disk, as producing half as many double-sided disks.

[0012] The simultaneous processing is achieved by combining twosubstrate disks together into a substrate disk pair or disk pair. A diskpair is two substrate disks that are oriented in a back-to-backrelationship with the back-to-back surfaces either in direct physicalcontact or closely adjacent with a slight separation. The separation canbe achieved with or without an intervening spacer. The substrate diskpair progresses through each process step in much the same way as onedouble-sided disk, but with only the outwardly facing surface of eachdisk in the pair being subjected to the full process. Thus, theoutwardly facing surface of each pair becomes the active or functionalsurface and the inwardly facing surface of each pair remain inactive ornon-functional.

[0013] For convenience and understanding, the following terms will havethe definitions set forth:

[0014] a) “R-side” and “L-side” refer to the active side and inactiveside of a disk, respectively. R-side is the side that does or will haveactive recording materials and memory capability. The R-side may also bereferred to as the active or functional side. The L-side is the sidethat has little or no active recording materials or memory capabilities;it is non-functional or inactive from a data storage stand point.

[0015] b) “Merge” means to bring two disks closer together to form apair of disks, a disk pair or a substrate pair.

[0016] c) “Demerge,” conversely, means that a merged pair of disks isseparated from each other.

[0017] d) “Disk” means a finished memory disk and all predecessorconfigurations during the manufacturing process starting with asubstrate disk and progressing to a finished memory disk, depending uponthe context of the sentence in which it is used.

[0018] e) “Disk pair” or “substrate pair” means two disks positioned incontact merge, gap merge or spacer merge orientation.

[0019] f) “Double-sided disk” means a single disk which has beensubjected to double-sided processing, whether or not both sides of thedisk have passed testing or only one side has passed testing.

[0020] g) “Gap merge” means a pair of disks that have been merged, but aspace is maintained between the two merged disks. One or more spacersmay or may not be used to maintain the gap or space. Gap merge includesboth concentric and non-concentric merge. It should be understood thatthere is no precise dimension or limit to the space between the disksthat causes them to be gap merged. Gap merge also includes the situationwhere the gap between the disks gradually decreases from one perimeteredge to the opposite perimeter edge of the disks when the two disks areangled toward each other. An example is when the bottom perimeter edgesof the disks are spaced apart and the upper perimeter edges are incontact.

[0021] h) “Single-sided disks” means a single disk which has beensubjected to singleside processing, where only one surface of the diskis fully processed.

[0022] i) “Spacer merge” means a spacer body is used to create spacingbetween two gap-merged disks.

[0023] j) “Contact merge” means a merged pair of disks where the insidesurface of each disk is in contact with the inside surface of the otherdisk. Contact merge includes concentric and non-concentric merge.

[0024] k) “Concentric merge” means that two merged disks have the sameaxis and, assuming the two disks have the same outside diameter andinside diameter (as defined by the center aperture), their outer andinner perimeter edges are aligned.

[0025] l) “Concentric contact merge” means a pair of disks that areoriented in both a contact merge and a concentric merge.

[0026] m) “Non-concentric merge” or “off-centered merge” means the twomerged disks are not concentric to each other or their perimeter edgesare not aligned.

[0027] n) “Non-concentric contact merge” means the two contact mergeddisks are not concentric to each other or their perimeter edges are notaligned.

[0028] Referring to FIG. 2, a cross-section of a pair of gap-mergeddisks is shown. The R-side (active or functional side) is the outwardlyfacing surface R of each disk within the pair. The L-side (inactive ornonfunctional side) is the inwardly facing surface L of each disk withinthe pair. In comparison, a cross-section of a pair of concentric contactmerged disks is shown in FIG. 3. The relative orientation of the R-sideand L-side of each disk remains the same, however, the L-side of eachdisk of the pair are in contact and the outer and inner perimeter P ofeach disk is aligned with the outer and inner perimeter P of the otherdisk.

[0029] A conventional double-sided disk is shown in FIG. 4. The leftside surface is referred to as the “A” side and the right side surfaceis referred to as the “B” side. Both the A and B sides are subjected toprocessing, including the addition of active or magnetic materials. Incontrast, with reference to FIGS. 2 and 3, the R-side of each disk in apair of disks is oriented on the outside of the pair and is subjected toprocessing in the same fashion as the A and B sides of a double-sideddisk. Conversely, the L-side of each disk in a pair of disks is orientedon the inside of the pair and is not subjected to full processing in thesame fashion as the A and B sides of a double-sided disk.

SUMMARY OF THE INVENTION

[0030] These and other benefits are addressed by the various embodimentsand configurations of the present invention. For example, a benefitprovided by one embodiment of the present invention is the ability tohandle and transport two disks or substrate disks as a single pair ofdisks. Another benefit is that the pair of disks can be positioned inclose proximity to each other, including being in a gap mergeorientation. The ability to handle and manipulate pairs of disks in thismanner affords yet another benefit which is the ability tosimultaneously process pairs of disks using existing processingequipment originally designed and built for manufacturing conventionaldouble-sided disks one at a time. In turn, these advantages allowincreased output in the production of finished disks by the ability toprocess two disks simultaneously.

[0031] In one embodiment, a lift saddle is provided for removing singlepairs of disks from a cassette, or for vertically transporting singlepairs of disks. The lift saddle includes two adjacent parallel groovesfor holding a pair of disks in gap merge orientation. The saddle iscurved to engage the disk pair along a bottom portion of their outerperimeter edge. A wedge or rib member may be positioned between the twogrooves to maintain the desired spacing or gap between the two disks.This embodiment is preferably used in the texturing and cleaningprocesses to remove disk pairs from cassettes or to return disk pairs tocassette.

[0032] In a second embodiment, a lift member is provided for alsohandling single pairs of disks in a gap merge orientation. In thisembodiment, the disk pair is engaged at three distinct and spaced apartpoints by three blades affixed to the lift member. The blades have adisk contacting edge that is generally W-shaped, forming twoside-by-side slots with a center rib or tooth to maintain gap mergeorientation. This embodiment is ideally suited for high temperatureenvironments such as sputtering.

[0033] A third embodiment is provided for handling and transportingmultiple pairs of disks positioned in gap merge orientation. In thisembodiment, a disk cassette or container has a series of grooves formedon the opposed inside surface of the side walls. The grooves are formedby an alternating series of large and small ribs. The large ribsseparate one pair of ribs from the adjacent pairs of ribs and the smallribs separate the two disks comprising each pair of disks. The large andsmall ribs also provide and maintain desired spacing in order that thedisk pairs may be efficiently engaged by other processing equipment.This embodiment, when constructed from high temperature resistant metalis preferred for use in the sputtering process.

[0034] A fourth embodiment is also disclosed for handling andtransporting disks. One unique aspect of this embodiment is itsinterchangeability and modularity. The four side wall members areidentical. If one or more wear out, they are easily replaced. Also, ifit is desired to alter the orientation of the disks, a differentlyconfigured side wall may be substituted. Similarly, side walls ofdifferent lengths can be substituted to provide cassettes that holdfewer or greater numbers of disks or that accommodate different diskthicknesses. This modularity allows disk manufacturers to readilyaccommodate different cassette configurations without maintaining aninventory of multiple types of cassettes.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035]FIG. 1 is a schematic of a double-sided disk manufacturingprocess, on the left, and a schematic of a single-sided diskmanufacturing process, on the right.

[0036]FIG. 2 is a cross-section of a pair of gap merged disks.

[0037]FIG. 3 is a cross-section of a pair of concentric contact mergeddisks.

[0038]FIG. 4 is a cross-section of a conventional double-sided processdisk.

[0039]FIG. 5 is a perspective view of one embodiment of the presentinvention removing a pair of disks from a cassette.

[0040]FIG. 6 is a front elevation of one embodiment of the presentinvention.

[0041]FIG. 7 is a side elevation of the embodiment of FIG. 6.

[0042]FIG. 8 is a cross-section taken along line 8-8 of FIG. 7.

[0043]FIG. 9 is an end plan view of the embodiment of FIG. 7.

[0044]FIG. 10 is a cross-section taken along line 10-10 of FIG. 9.

[0045]FIG. 11 is an enlarged partial cross-section of a secondembodiment of the present invention.

[0046]FIG. 12 is a front plan view of a third embodiment of the presentinvention.

[0047]FIG. 13 is a front elevation of a blade element.

[0048]FIG. 14 is an enlarged partial perspective of the embodiment ofFIG. 12.

[0049]FIG. 15 is a top plan view of a fourth embodiment of the presentinvention.

[0050]FIG. 16 is an end elevation view of the embodiment of FIG. 15.

[0051]FIG. 17 is a partial enlarged view of the embodiment of FIG. 15.

[0052]FIG. 18 is a cross-section taken along line 18-18 of FIG. 15.

[0053]FIG. 19 is an enlarged detail of the cross-section of a side wallof the embodiment shown in FIG. 15.

[0054]FIG. 20 is an end plan view of a fifth embodiment of the presentinvention shown in FIG. 28.

[0055]FIG. 21 is a side plan view of the embodiment of FIG. 20.

[0056]FIG. 22 is a top plan view of a side wall member of the embodimentshown in FIG. 28.

[0057]FIG. 23 is an end plan view of the embodiment shown in FIG. 22.

[0058]FIG. 24 is an enlarged detail of the portion of the embodimentshown in FIG. 22.

[0059]FIG. 25 is a front plan view of the base member of the embodimentshown in FIG. 28.

[0060]FIG. 26 is a top plan view of the embodiment of FIG. 25.

[0061]FIG. 27 is an end plan view of the embodiment of FIG. 25.

[0062]FIG. 28 is a perspective view of a fifth embodiment of the presentinvention.

[0063]FIG. 29 is a top plan view of the embodiment in FIG. 28.

[0064]FIG. 30 is a cross-section taken along line 30-30 of FIG. 29.

[0065] It should be understood that the drawings are not necessarily toscale. In certain instances, details which are not necessary for anunderstanding of the invention or which render other details difficultto perceive may have been omitted. It should be understood, of course,that the invention is not necessarily limited to the particularembodiments illustrated herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0066] In one embodiment of the present invention, a transfer tool orlift saddle 10 is provided for transferring a pair of disks in a gapmerge orientation either from or to a cassette or container 12. As shownin FIG. 5, the lift saddle moves vertically through the bottom and topopenings of the cassette between a first position beneath the cassetteto a second position generally at or near the top of the cassette. Inits movement between lower to upper positions, the lift saddle engagesand lifts two disks from a cassette and transfers them to a positionwhere the pair of disks are engaged by other automated processingequipment. The other processing equipment may include a second transfertool which moves the pair of disks to another location for processing.Alternatively, the disks may be processed on the lift saddle at itsupper position. The lift saddle is also used to return the pairs ofdisks to a cassette following processing.

[0067] With reference to FIGS. 6-10, the lift saddle comprises a mainbody 14 with a curved or arcuate disk engaging portion 16. The radius ofthe curved or arcuate shape is intended to approximate the radius of thedisks. However, if the lift saddle will be used in processes thatincrease the temperature of the disks, such as sputtering, the curveshould be slightly larger than the radius of the disk to accommodatethermal expansion of the disks. As best seen in FIG. 8, the diskengaging portion has a generally W-shaped cross-section comprising twoadjacent parallel grooves 18. More specifically, a center ridge or rib20 is provided to maintain the prescribed spacing between the pair ofdisks. Thus, two channels are provided, each designed for separatelyengaging and holding one disk of the pair in a gap merge orientation.The bottom of each channel, formed by the outer side wall 22 and innerside wall 24, terminates at an apex 26, as shown in FIGS. 6, 8. Theangle formed by the inside and outside walls of each channel is designedto provide a width to the channel sufficient to accommodate theparticular thickness of the disks, as well as to generally match anychamfer formed in the outer perimeter edges of the disks. (See FIG. 6.)If the disks are chamferred, the angle of the side walls and chamferpreferably match, providing additional stability in holding the diskduring transport operations. In a second embodiment of the lift saddle,shown in cross-section in FIG. 11, the channels 18 may be formed with aflat bottom surface 28. The width W₃ of the flat portion preferablymatches the thickness of the disk, minus the chamferred portions of thedisk perimeter edge, if any.

[0068] In one embodiment, a cutout or hollow portion 30 is provided inone side of the main body 14 of the lift saddle to accommodate thedistal end of a lift rod 32. The lift rod moves the saddle verticallybetween its lower and upper positions. A pair of apertures 32 areprovided in the main body of the lift saddle to accommodate lockingscrews or other securement devices to secure the lift saddle to the liftrod. As best illustrated in FIG. 8, the cutout portion 30 allows thelift rod to fit flush within the main body portion to minimize the widthof the lift saddle. This permits the lift saddle to be utilized withconventional double-sided disk processing equipment and to move a pairof single-sided disks within spaces originally designed and built toaccommodate a single double-sided disk. For example, the width W₁ of thesaddle illustrated in FIG. 8 is 0.250 inches. The center-to-centerdistance of the two channels W₂ is 0.085 inches and the angle formedbetween the side walls 22 and 24 is 30 degrees (FIG. 8). This geometrywill accommodate two disks with a thickness of 0.050 inches, as shown inFIG. 6. This is important because the disk temperature is ambient (roomtemperature) at the beginning of the sputtering process and may approach300 degrees Celsius during the sputtering process. Moreover, at thiselevated temperature, the disk will expand, perhaps by as much as sevenpercent.

[0069] It should be appreciated that the dimensions of the disk engagingportions of the lift saddle can change depending upon the size of thedisks involved. In addition, the lift saddle may be machined from asingle block of high-temperature-resistant material to not only providegreater precision and accuracy in forming the disk engaging portions 16of the saddle, but to allow the lift saddle to operate in hightemperature environments during disk processing. During processing ofhard memory disks, the disks are subjected to temperatures that canreach 350 degrees Celsius. One example of a high temperature environmentis the sputtering process where pairs of disks will be removed from acassette, subjected to numerous sputtering steps and ultimately returnedto a cassette. Machining of the disk contact surfaces, such as insideand outside walls 22, 24 of the two channels 18, allows the lift saddleto handle both hot or cold disks. Acceptable metals that can withstandthese extreme temperature changes include 304 and 316 stainless steel(full hard). Alternatively, depending upon the application environment,the disk saddle may be made from plastic. For example, for lowtemperature environments, such as below 40 degrees Celsius, the liftsaddle may be molded from polyesteresterketone (PEEK). PEEK providesgood rigidity and is not abrasive. In high temperature environments,such as up to 350 degrees Celsius, the lift saddle also may be made frompolyesteresterketone. Examples of this are sold under the trade namesVespel or Ultem.

[0070] A second embodiment of a transfer tool or lift member 40 is shownin FIGS. 12-14. Unlike the transfer tool of the first embodiment, thelift member shown here contacts each disk in three discrete locationsrather than over an extended perimeter edge. Thus, the amount ofphysical contact between the lift member 40 and the disks issubstantially reduced compared to the lift saddle 10. As a result, thelift member 40 is more suitable for sputtering or other processes whichadd material to the surface of each disk. Such processes can proceed ina less obstructed manner relative to the R-side of the disks.

[0071] The second lift member includes a body 42 and three single-piecedisk engaging members or blades 44. In the preferred embodiment, theblades are permanently fixed to the lift member 40 and are not capableof adjustment. However, in one alternative embodiment, the blades areadjustably attached to the lift member by set screws 46 or other meansto allow positioned adjustment of the blade relative to the body. Theblade may include three apertures 48, 50, 52 for this purpose. Thecenter aperture 50 may be enlarged to permit fine adjustment of theblade's position. This also permits the three blades to be properlyaligned relative to each other to optimally secure the disks. The outerapertures 48, 52 may be secured to any of a series of securement holesin the lift body (not shown), whose relative positions are predeterminedto accommodate disks of different diameters. The removeability permitsreplacement of the blades due to wear or for other reasons.

[0072] As shown in FIG. 13, the blades 44 have a disk engaging edge 54that is generally W-shaped for engaging, holding and maintaining thedesired gap merge orientation of the pair of disks. As shown in FIG. 14,the edge of the blade is designed with teeth 56, 58, 60 to permitcradling of each disk along the perimeter or outer edge of the disk. Asshould be appreciated, the profile of the blade can vary for differentpurposes, such as maintaining different spacing between the disks oraccommodating different thickness of disks. Also, the profile of theblade edge may be designed to match or maintain spacing imparted to diskpairs by other equipment. For example, in the sputtering process, pairsof disks may be transferred from a cassette to a lift member 40 to otherprocessing or transfer equipment and back through this chain of handlingequipment to the cassette. In such a context, it would be preferablethat the spacing of the disks be consistent to facilitate transfer amongthe various pieces of equipment. As a result, disks may be transferredwithout change of spacing or orientation of the disks.

[0073] In one embodiment primarily intended for sputtering, the angle A,shown in FIG. 13, is between approximately 100 and 110 degrees. A wideangle such as this intentionally avoids contact between the blade edge44 and the data zone of the disks so that the sputtering process is notimpeded on the R-side of each disk. With reference to FIG. 12, the outerblades 62 are disposed at an angle B relative to the vertical centerline of the disk, which is defined by the center blade 64. In thisembodiment, angle B is 55 degrees. The lift member and blades may bemade from high temperature resistant material, such as 304 or 316stainless steel (full hard), in order that it may withstand hightemperature environments. When working with disks having a thickness ofabout 0.050 inches, the blade is preferably 0.250 inches wide and 0.015inches thick.

[0074] A third apparatus for handling pairs of gap merge disks is shownin FIGS. 15-19. As illustrated therein, a cassette 70 is provided fortransporting disks grouped in pairs. In the preferred embodiment, thecassette will accommodate 25 pairs of single-sided disks (50 total) inthe same space as conventional cassettes carrying 25 double-sided disks.In other words, two disks having a 0.05 inch thickness, individually,can be positioned every 0.25 inches along the length of the cassette,rather than one double-sided disk.

[0075] In one application, the cassette is used as part of thesputtering process where the disks reach substantially elevatedtemperatures, up to 350 degrees Celsius. In this application, thecassette may be machined from a single block of aluminum or otherheat-resistant metal to accommodate the high temperatures. Machining thecassette from a single block of metal also eliminates the need formultiple piece cassettes held together by fasteners or screws. Thejoints and apertures in such multi-piece cassettes can introducecontaminants into the sputtering process which requires a high degree ofcleanliness (a level 10 clean room). As should be appreciated,contaminants can ruin an entire batch of disks. In the preferredembodiment, the cassette will be plated to improve abrasion resistancebetween the disks and the cassette, thereby reducing potentialparticulate contamination on the disk surfaces. An appropriate platingmaterial is nickel.

[0076] Referring to FIGS. 15 and 17, a series of marks or holes 72,precisely aligned, are machined along the top edge 74 of the side walls76 of the cassette to allow positive positioning of the cassetterelative to the processing machinery. Ideally, one alignment mark 72 ispositioned adjacent each pair of gap merge disks. In FIG. 17, the marksare positioned adjacent the gap between the two disks comprising eachpair of disks. Known optical and mechanical systems maybe used forpositioning the cassette based on these alignment marks. They may alsobe used to index the position of the cassette relative to the processingequipment as successive pairs of disks are removed and returned, untilthe entire batch of disks has been processed. The alignment holes aremachined to allow bi-directional alignment of the cassette relative tothe processing equipment and other machinery.

[0077] A row of ribs 78 designed to accommodate and position the pairsof disks is disposed along the inside surface 80 of the side walls ofthe cassette. As best seen in FIG. 19, the row of ribs comprise a seriesof alternating large and small ribs 82, 84, respectively. The large ribsseparate pairs of disks from adjacent pairs of disks, and the small ribsmaintain separation of the two disks comprising each pair of disks. Inthe preferred embodiment, assuming the thickness of the disks permits, apair of disks is placed every 0.25 inches along the length of thecassette. The spacing between the two disks of each pair is created bythe small rib 84 and is between approximately 0.025 and 0.035 incheswhen dealing with disks having a 0.050 inch thickness. A pair ofchannels or grooves 86 are formed between the ribs 82 by each rib 84.The channels 86 and ribs 82, 84 position pairs of disks in a gap mergeorientation. The end walls 88 of the cassette also include a cutout oropening 90 to allow access to the central aperture formed in each disk.

[0078] As previously mentioned, one use for this metal cassette is inconnection with the sputtering process, or any process where the disksreach high temperatures, such as approaching 300 degrees Celsius. Inthis high temperature environment, gap merge orientation of disks isalmost a requirement. If pairs of disks are placed in contact mergeorientation after reaching approximately 300 degrees Celsius, thealuminum substrate or core could literally melt.

[0079] A second cassette 100 for holding a plurality of pairs of disksin gap merge orientation is shown in FIGS. 20-30. The cassette is madefrom three modular pieces, eight pieces in total. Its modular natureallows for the replacement of worn pieces or interchangeability ofdifferently configured pieces. Thus, as will be apparent to one skilledin the art, the cassette can be reconfigured to position disks indifferent orientations, such as gap merge or other configuration neededduring disk processing. In addition, the length of the cassette can bechanged to carry different numbers of disk pairs. In a preferredembodiment, this cassette would be made from plastic and, therefore,have its use limited by the characteristics of the plastic employed tomake the cassette.

[0080] The end walls 102 are generally U-shaped to allow access to thedisks and include six apertures 104 for attachment of the othercomponent pieces. The U-shaped opening 106 provides access to the disks.A pair of base wall members 108, shown in FIGS. 25, 26, are attached tothe end walls through securement holes 110 in the base wall members andin the end walls. Screws or other fasteners are used to attach the basewall to the end walls. In addition, four side wall members 112 areattached between each end wall to provide disk support surfaces. Allfour side wall members shown in FIGS. 28-30 are identical to each other.A single side wall member is shown in FIGS. 22, 23.

[0081] The inside surface 114 of the side walls, shown in FIGS. 22 and28-30, include a row of teeth, alternating between a large size 116 anda smaller size 118. In the preferred embodiment, and as shown in FIG.23, each side wall is octagonal in cross-section.

[0082] With reference to FIG. 24, an enlarged view of the profile of onegap merge disk support groove 120 is shown. A pair of large teeth 122are separated by an interspaced smaller tooth 124. The side wall of thelarge teeth have two surfaces, a base portion 126 and an upper portion128. The angle formed by the upper portion of the side walls of theadjacent large teeth is 60 degrees. The base portions of the side wallsform a 90 degree angle. The angle of the base portion is designed toaccommodate chamfers in the outer perimeter edges of the disks.Precision manufacture of these grooves allows maintaining consistent andaccurate alignment of the disks, which is necessary for the precisehandling required for single surface processing. It should beappreciated that the configuration of the teeth or ribs can be modifiedto accommodate different alignment, orientation or spacing among thedisks. Thus, side walls 112 having disk support surfaces thataccommodate other disk orientations may also be utilized. A gap mergeorientation cassette is described in co-pending U.S. patent applicationSer. No. ______ (to be assigned) entitled “Cassette Apparatus forHolding 25 Pairs of Disks for Manufacturing Process” (Attorney DocketNumber 3123-523), filed May 9, 2003, the entirety of which isincorporated herein by reference as if stated herein.

[0083] Merging of disks may be further facilitated by use of a mergenest. A merge nest works in association with a disk cassette and assistsin merging pairs of disks into a desired orientation, such as gap mergeorientation. An example of a merge nest is described in co-pending U.S.patent application Ser. No. ______ (to be assigned) entitled “AutomatedMerge Nest for Pairs of Magnetic Storage Disks” (Attorney Docket Number3123-521), filed May 9, 2003, the entirety of which is incorporatedherein by reference as if fully stated herein.

[0084] It should be appreciated that the variations in theabove-described embodiments may occur to those of skill in the artwithout departing from the spirit and scope of the present invention.For example, the cassette may be designed to hold any number of diskpairs. The disk support surfaces formed by the teeth in the side wallsmay be configured to support disks of different thickness and differentspacing between disks. The cassette may be made of high-temperaturemetal, as well as any other material suitable for its intended purpose,depending upon the environment in which it will be placed. It ispreferred that abrasion-resistant materials be used to reducecontamination to the disks during processing.

[0085] The foregoing discussion of the invention has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the invention to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of theinvention are grouped together in one or more embodiments for thepurpose of streamlining the disclosure. This method of disclosure is notto be interpreted as reflecting an intention that the claimed inventionrequires more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the followingclaims are hereby incorporated into this Detailed Description, with eachclaim standing on its own as a separate preferred embodiment of theinvention.

[0086] Moreover, though the description of the invention has includeddescription of one or more embodiments and certain variations andmodifications, other variations and modifications are within the scopeof the invention, e.g. as may be within the skill and knowledge of thosein the art, after understanding the present disclosure. It is intendedto obtain rights which include alternative embodiments to the extentpermitted, including alternate, interchangeable and/or equivalentstructures, functions, ranges or steps to those claimed, whether or notsuch alternate, interchangeable and/or equivalent structures, functions,ranges or steps are disclosed herein, and without intending to publiclydedicate any patentable subject matter.

What is claimed is:
 1. A method for manufacturing hard memory disks,comprising: a. orienting a pair of disks on a transfer tool such thatthe disks are positioned in parallel axial alignment with a spacebetween them; b. moving the pair of disks from a first location to asecond location; c. simultaneously processing the pair of disks.
 2. Themethod of claim 1, further comprising while simultaneously processingthe maintaining of the pair of disks on the transfer tool.
 3. The methodof claim 1, further comprising placing the disk pair in the cassettewith transfer tool, following processing.
 4. The method of claim 1,further comprising placing the plurality of disks in the cassette, priorto orienting the pair of disks on the transfer tool.
 5. The method ofclaim 2, wherein said processing comprises subjecting the pair of disksto temperatures of at least approximately 350 degrees Celsius.
 6. Themethod of claim 2, wherein said processing comprises adding material tothe outwardly facing surface of each disk.
 7. The method of claim 6,wherein said processing comprises sputtering.
 8. The method of claim 6,wherein said processing comprises deposition.
 9. A method of handlingsingle-sided hard memory disks, comprising: a. positioning a pair ofdisks in gap merge orientation on a disk handling device at a firstlocation; b. moving the pair of disks from the first location to asecond location using the disk handling device.
 10. The method of claim9, further comprising transferring the disk pair to a second device atthe second location.
 11. The method of claim 9, further comprisingmoving the disk pair from the second location to the first locationusing the disk handling device.
 12. The method of claim 9, furthercomprising placing a plurality of pairs of disks in a container prior topositioning a pair of disks on the disk handling device.
 13. The methodof claim 12, wherein said first location comprises a disk container. 14.The method of claim 9, wherein positioning a pair of disks in gap mergeorientation on a disk handling device at a first location comprisesforming a gap between the disks of approximately 0.035 inches or less.15. A method of manufacturing single-sided hard memory disks,comprising: a. positioning a carrier containing a plurality of disks inparallel axial alignment at a first location; b. positioning two diskson a transfer tool in parallel axial alignment, with one surface of eachdisk in a face-to-face orientation and with a space between thesurfaces; c. removing the pair of disks from the carrier using atransfer tool; d. simultaneously processing the pair of disks; e.returning the pair of disks to the carrier.
 16. The method of claim 15,further comprising maintaining the orientation of the disk pair on thetransfer tool during processing.
 17. The method of claim 15, furthercomprising removing the pair of disks from the transfer tool prior toprocessing.
 18. The method of claim 15, further comprising changing theposition of the carrier following the return of a pair of disks to thecarrier.
 19. The method of claim 15, further comprising repeating thesteps of positioning, removing, processing and returning until all disksin the carrier have been processed.
 20. The method of claim 19, furthercomprising: a. positioning the carrier at a second location; b.positioning two disks on a transfer tool in parallel axial alignment,with one surface of each disk in a face-to-face orientation and with aspace between the surfaces; c. removing the pair of disks from thecarrier using a second transfer tool; d. simultaneously processing thepair of disks; e. returning the pair of disks to the carrier.
 21. Themethod of claim 20, further comprising repeating the steps ofpositioning, removing, processing and returning at the second locationuntil all disks in the carrier have been processed a second time. 22.The method of claim 21, wherein the first processing step differs fromthe second processing step.
 23. The method of claim 15, wherein saidpositioning of a carrier at a first location further comprises aligningthe carrier using alignment marks disposed on the carrier.
 24. Themethod of claim 15, wherein said carrier is made with aluminum.
 25. Themethod of claim 23, further comprising adjusting the position of thecarrier at the first location using the alignment marks followingreturning a pair of disks to the carrier.
 26. The method of claim 15,wherein said carrier is made from material resistant to temperatures ofat least 350 degrees Celsius.
 27. The method of claim 15, wherein saidcarrier is a single piece of metal.
 28. The method of claim 15, whereinsaid carrier is plated for abrasion resistance.
 29. The method of claim15, further comprising placing a plurality of disks in a carrier priorto positioning a carrier at a first location.
 30. The method of claim29, further comprising placing up to 50 disks in the carrier.
 31. Themethod of claim 29, wherein said step of placing a plurality of disks inthe carrier comprises orienting the disks in parallel axial alignmentand in pairs with a space between the disks, and wherein the spacebetween disks within a pair is no greater than the space betweenadjacent pairs of disks.
 32. The method of claim 31, wherein the spacebetween adjacent pairs of disks is larger than the space between thedisks comprising each pair.
 33. The method of claim 15, whereinpositioning two disks on a transfer tool comprises engaging a length ofthe outer perimeter edge of each disk.
 34. The method of claim 33,wherein engaging a length of the outer perimeter edge of each diskcomprises placing the disks in parallel adjacent grooves formed in thetransfer tool.
 35. The method of claim 34, wherein placing the disks inparallel adjacent grooves further comprises locating a separating memberbetween the disks.
 36. The method of claim 33, wherein engaging a lengthof the outer perimeter edge of each disk comprises engaging an outerperimeter edge of the disks along the bottom of each disk.
 37. Themethod of claim 15, wherein removing the pair of disks from the carriercomprises moving the transfer tool vertically between a positionsubstantially beneath the carrier and a position such that the pair ofdisks are above the carrier.
 38. The method of claim 15, furthercomprising transferring the pair of disks to a second transfer toolfollowing removing the disks from the carrier using a transfer tool. 39.The method of claim 38, further comprising moving the second transfertool to a second position following transferring the pair of disks to asecond transfer tool.
 40. The method of claim 15, wherein positioningtwo disks in a transfer tool comprises engaging each disk at threelocations.
 41. The method of claim 40, further comprising engaging thetwo disks at three locations spaced around the outer perimeter of thedisks.
 42. The method of claim 40, wherein the three locations aresubstantially evenly spaced apart.
 43. The method of claim 15, whereinpositioning two disks on a transfer tool does not block access to theoutwardly facing surface of either disk.
 44. The method of claim 40,further comprising maintaining the orientation of the disks on thetransfer tool during movement of the transfer tool.
 45. A method ofrepairing carriers used to store and transport hard memory disks, themethod comprising: a. providing a disk carrier having separate,connectable and detachable components comprising two end walls and aplurality of side walls; b. maintaining a supply of additional end wallsand side walls; c. detaching from the carrier one or more components; d.replacing the detached one or more components.
 46. The method of claim1, wherein the end walls are identical.
 47. The method of claim 1,wherein the plurality of side walls are identical.
 48. The method ofclaim 1, wherein maintaining a supply of additional end walls and sidewalls comprises maintaining a discrete inventory of such components. 49.The method of claim 1, wherein maintaining a supply of additional endwalls and side walls comprises maintaining additional assembledcarriers.
 50. The method of claim 1, wherein providing a plurality ofside walls comprises providing side walls configured to hold disks inpairs, and each pair in a gap merge orientation.
 51. A method ofhandling hard memory disks having different thicknesses comprising: a.providing a disk carrier for holding a plurality of hard memory disks;b. forming the carrier from attachable and detachable component piecesconfigured to accommodate disks having a first thickness; c. detachingthe component pieces configured to accommodate disks of the firstthickness; d. attaching different component pieces in place of thedetached component pieces, with the different component piecesconfigured to accommodate disks having a second thickness.
 52. Themethod of claim 7, further comprising detaching the side walls andattaching different side walls.
 53. The method of claim 8, furthercomprising providing side walls configured to position disks in pairs,with each pair of disks positioned in a gap merge orientation.